How is Rockpanel cladding made?
To find out how sustainable Rockpanel facade cladding is produced, we need to zoom into the production process:
How Rockpanel facade cladding is produced? From spinning lava to coating the pressed boards: we will take you through the production process of Rockpanel step by step.
To find out how sustainable Rockpanel facade cladding is produced, we need to zoom into the production process:
Rockpanel facade cladding is made of stone wool fibres. All stone wool used for products made within the ROCKWOOL Group is created in the ROCKWOOL factories. To create stone wool fibres, a combination of basalt (which is solidified lava), recycled stone wool and secondary raw materials is heated to a temperature of about 1500 °C – as hot as a volcano. The production process for stone wool fibres actually is a technological replica of the inside of a volcano. A spinning machine whips the melted basalt into thin strands of stone wool. You could compare the process of making stone wool to how candy floss is made.
The stone wool fibres are collected and baled for transport and storage. The material is then ready to move on to the Rockpanel production lines.
On our press line, the stone wool is being pressed into a high-density board. For the binding of the stone wool fibres, a small amount of thermosetting resin is used. This creates a panel with a low calorific content and very good reaction to fire performance.
Production waste is fully utilised in this process: every piece of stone wool that’s cut off, goes back into our recycling process and is used to create new stone wool fibres. And thanks to our unique and highly efficient manufacturing process, we are able to produce more than 400 m² Rockpanel boards from only 1 m³ of basalt.
The next step is to finish our boards with a coloured coating. We use a waterborne coating system which has a high durability. With our modular system we can create all kind of designs, from unicolour boards to Woods, Stones, Metals or Chameleon designs.
Afterwards, an extra protective layer can be applied. This ProtectPlus coating creates a self-cleaning anti-graffiti surface with improved weathering resistance and optimal UV resistance for an even more durable result.
During this stage the paint lines are cleaned with water – the only time water is used at the Rockpanel production facility. The total amount of water used during this process is less than 3.000 m3 (in 2021 exact use was 2.804 m3). Afterwards the water is sent to the recycling plant of ROCKWOOL helping to reduce the amount of fresh water needed.
We produce more than 400 m² Rockpanel boards
From only 1 m³ of basalt
Every single year, the ROCKWOOL Group continues to make progress towards our sustainability goals. Download our Sustainability Report to learn more about our progress, achievements and our new commitments.
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We manufacture board material mostly used in ventilated constructions, for facade cladding, roof detailing, soffits and fascias.
